Kawasaki Ninja 250 Manual

.',Ninja250RKawasaki GPX250RMotorcycleServiceManualSupplementQuickReferenceGuideBrakesEngineLubricationSystemAppendixWheels/TiresElectrical SystemEngineRemoval/InstallationCrankshaff/TransmisslonFinal DriveGeneral InformationThi s q uick rel..ol'lOt !JJide will ...i.l youinlocating I desired tap;cOfprOCOdUfl .lO8. nd 1110 Plgoo bock 10 m. td1 the blocktob of th . desi..-d ch epler " umbo r with\11. black tab on Iho edge II l och labl .01 """,tlntl p .IR,f" 10lho ~ o n . 1 lObi. of """tent> 'Ofth l l uet pages to100011 I.... specifictopicrequ i'td,KawasakiNinja250RGPX250RMotorcycleServiceManualSupplementAll rightsreserwd. fIIo J*'!' 01 this publQtionITIlIybe. ep rod uced . nOted in 8 ntrieval system,ort ransmitted in"''1form0# by "''1mMI'lI, elec1l'onicmec han ical photocopying, recordil19orothtr-WiM, without Ihe pr ior _menpenni.ion of Ouality A-...I IlCll Oepertment/CoI'llUfTlWProducts ..Components G,oup/K_ _ ki H. ..y l ndun, in, l td., Japoln.No liabilitycanbe acceptedfo. eny in8CCUraciesor omissions inttl;s PIlbliut ion, alt hough -VpoMib le c;orehasbeen ta ken 10 make it as campl118 and accurate at possible.Theright isreservedtomake CN nqesal any ti mewit hout priornot ic.andwit tloutincurringaoeoOf p_Clu""F,ict _ fol . _ ...I.......' .....-._-_.-.- . ,!," .-.- ..,n . " .Ut" V ,",,,ou," onou":i\i"'H""".." ",,,,-, "'-'.' '; .. . "." "l0t;.;"'."Col"", ,,-"oi." ' ;.: "., '''','''iI """L''.. _if.. l'". . II"':V;;. ... ./\"7;;'. .....:v.; ,y " " _ . .. ..'-"..- ... !> ".!f1....point solven t isrncommended to fi re d.,ger. A eornmen::illl$OIvent c0m-monly ..... labI. inNorthAmericais Stoddard sdvent 1generic n....... !. Always followm...... fiCtlJrer and COOllin regardin... the u. o f an y solvent.181G.ke!. O-ringDono l flUSI a or O-ring onceit h.been inservice. Th. mali..... surf8Cl!$ aroondthelIiSkel shouldbefree o fforei gnmat ter andperfectlv smoolhtoavoidoi l0 ' compression I. akl ,191 Liqu id Gasil. t Non pennanentLocking AgentFol lowmanu lectu re, s di rect ionsforcleaningandprepar ing .., rfaocn wherethese compoundswill be usad, ApplyIparing y. h ceuiveamountsmayblockerrgineoi l passages ar)lj Cal1eseriousdamage, Anexamp le of I non-perm..,ent lockingagent common lyavailableinNor thAmerica is Loctit e Lock' n Seal (Blua!.(10) PressApart insU! lled using apreS'S ordriver. such a.a wheel bearing. shou ld first becoa led with oilonltsOUler or inner circumference 10 matit will 90intoplace Imoothly,1111Ball BearingWIl eninstalling I ballbearing. thebearing, _ whichilaffectedbyfrict ion shou ld be pul hedbyalUitable drive, . This pnNents_ '. $lreII on thebeusandr8CM, andpreventsraces andbal lt; frombeingdented. Press a ball bearinll unt il 'I . to ps at the $lOPin the hole or On !he Ihaft.GENERAL INFORMATION 1-3(12)Oil Seal and Grease SealReplaceanyoil or grease seals that wereremoved withnew ones, as removal generally damagesseals.Whenpressing in aseal whichhasmanufae lurer'i marks, press it in witnthemarks facing OU1.Seals shouldbepressedintoplaceusing a suitabledriver, which contacts evenly withtheside ofseal, unti l the face ofthe seal is even with the endof the hole .1 1 3 ~ Seal GuideA seal guideis required forcertainoil or graase seels dur ing inst allat ion toavoid damage tot heseal liP'S. Before ashaft passesthrough aseal, appiyalittleoil, prefarablyhightemperaturagrease on the lips toreduce rubber to metal frict ion.114) Circlip, Retaining RingReplace anycircllpsandretainingrings that wereremO'ledwithnew ones, as removal weakensanddeformsthem. Wheninstalling circlips andretainingrings, t ake care t o compress or expandthemonly enough toinstall themand no more.(15) LubricationEnginewear is general lyat its maximumwhiletheengine is warmingupandbefore all therubbing surfaceshave anadequaterubrtcenvefilm. Duringassembly, oil or grease (whichaver ismoresuitable) shouldbeappliedtoanyrubbingsurfltCe whichhaslost it s lubricat ive film. Oldgrease anddirtyoil shouldbe cleaned off . Deteriorat ed grease ha'l lost its lubr icative qualitv andmay contain abrasive foreign part icles.Don't usejust any oil orgrease. Some oils andgreasesinparticular should be usedonlyincertein epplications and may be harmful if used in an appl ication fo r which they are notintended. Thismanual makesreference to molybdenum disulfide grease (MoS, ~ in the assemblyof cert/linengineend chassisparts . Always checkmanufacturerrecommendat ionsbeforeusingsuch special lubricants.(16l Electrical WiresAll the electrica l wires areeit her single-t bothond" thocobl. 'lhould "'me freely wi!hin tho o.b1e hou,ing.C, ThrottleA, Lo< .... a Ihin of !II"eWARNING in mef .... l evel l_ , ion.oDr. inthoruel 0111of Iheinto . ""iublamenumber ofturn. ,000nl cd duringdi,."embly.oFor the US model, in' tall the pilol re.... plug .,follow'In,tall Mw piug in t he pilot ' c'e....hole. and apply d,ma ll amnunt of a bondingagent to the circumforence of t he plug to h t hep l u ~ .1. Applyboodiol"il"M.2. Plug). Pi lot ""r,,,.4. C.,burew,bodyFUEL SYSTEM26lCAUTlOJil 'COD prMoocI _ _, __.. "... -'f "'" ...- lor .. _ . . ... tho- .-.-...""'....-'f bo ...., a, .OR-.... -..",w- Of_ "- tho_"'-._We...... 'I ' ,... tho __... 11IIo _ .........don. Tl>is ",ill _I __... 01tho po, tI.en.. _bwftor -., 1180 p1.nic '*"thol _I bo,,_. DONOTMOO 0. tt..... _burolO' oolulion wlllcII Id ottodc 1hftt Pl!'U; In.rood, use Imild11 11'11 ol....lng , o!ul lon ..10 forpIo.U..n.000n01 UIO .. i" orony0011.. h"d In.trumanl ' o ....n_bo............. Hpor;ially iotl. .. ""'" _y bo_.ICAUTlOJil ICOonot ., __-.... _ . ..... P'ulI '"1lwI _ _ ' ...... -._.01l'hen... _,the ......tiftl tf'Irid>or ... """"..,.the "",,,,,ti,,. W IOWl, reono>'O the o:oo inwoT..1, iMpee U10b ..ri" t to ItfI. il 10dtcd_...f \be pilol Kth' k or tWnoged on"'" portion, il * ,11 pr , tho mlln. nom ;'Ii".,nfC,o, hly, Replk. il .th., the ..mpi,''''' ....-. ,,"oothlyion thec ",rf "" of "'" pl, 1on ......., not be. xce;'i"'ly . ' fme rn pi>!"., doe, notmo.. ,",oomly. 0' if iti, very I""", in corbur. t ot body, rcplaCh point ",I venl,, ndl hendryhwithrompres>ed air or by shaking it.I WARNING I000not u.. lIIIJOlin. or lowf1..h-pomt oolnt tocl... n .....Iem. nt . AIi..orexplosion0>u1d r..ult.81eathe r Oil InspectionRemovet he plog at theend oft hedrain lube on lhO the . ir ele. ner element (,ee Air Ci.'int rElemenlRcmo..I).80(1.." the, ir deaner element (,eeAir Cle. ner ElementCle.ningl.eVi, ually inspect Ihe element 10f t"." or br..k, . Checkl he elemem holder . nd wire """"n.A. Screen" If il h.. any Ie." or break"replace t he element."I flhe holder orlhe roen Me dinoned, replace lhem.cWhen replacingthe holder Ot ", recn, remove theaircte..,er hou' ingand ", parale iIe Repe. led oft he foam in theelement. Replacet heclemenl "C"'ding10 Ihe Peri-odio Mainlooi"' .I WAJlHIHG00_ ... _kNo _I-nntilo-tool -. _ - --__ II .... _ k or fto_ ..ywtoooo _ lito_ .... __of 11>0-'"of .....11 ............ liQooidl. .... "'"_ .......... or __-.poin,.... _ ... c1_tI>o_.. Pour tho >01....1out of t ho unk.. R. ....... thefur lfromIhetan kby W;. inl out theholt, with nylon ...0:;11 with nyIcn......-a.ea tho fuel f&l' iii ... ,,;ramlor any tftalorouc"-... i_ no.. ......' be m_ .1 tile inlOro -.ill. , .. _ ._1MnI --"IVI._ tty _ . II tf>o -.it... ........................... it ...i .... _ _ .I TO _Ithe llN>Iine h omflo"";", in.., tiltUnlsl'"or from .....inl oulof theCMIi'l1". I'IoIdthe _.torpoerpendio:.ular 10 the Found.I 1br hoo.e> """",din, to !he di._of the.yot.... . "' ... ......thand othe rd.m"o,I lf tho . op..-. t o, h" . n crack '"!l. d . .... pl4loce it",i lh . new"""..onOTlN! c.niftw.. cIor , lid10 _ _ Ih""'fIhIf>omt>tt:>teydo'S .wfl'>out " /I _ _ i f it ;, ..-1

,,"- Cont rolSy. .. m. Emi ..,,,,,epo,."'"FUel SYSTEM2-191 FudTank" Carbureto r , , . ' ne' Hoo' in3 Ce. Sep.,at"r4: Uquid,IV. por5. C.ni" e, oo,c (Bluo)6 Bre. the'H H< coolin!is brown, ironOf " ..I pIl1\ lie tu,';ns. In .i!her """,ftu>h lh. on11>.iii... un... obnorm. 1 ""etl ""'...ch. nging, checkfOf cooling ,y' lem I . It m.y t>oC4udga, le" ing inl O the cooling ,y,I.m,NOTE,,*...,. ", "",-I, .. m. _ i .... If".. c:ooI.., If "":br>by " Of".. ,.u_ .,...".. .;. m UJ\' to.from Cool/..r Inspeerion_Si, u", " Ih. mOIO",Yci. '" l h,t hi, p< rpcnui, ul.r tolhegr.. . ,md(.... il< ",nlf < l OW_k>NOTEr>Cll* rt>. /rIIt1J _ "., ...,;... iocokJ (roomor...-.I 000 nor ,;,.by _ .....Of ,;,. CICI. If,;,. UP;, ......OI.d. Ii, __ lI"' ;"fO';" e>I4nr..__cooIn.,_-..y.3.0 COOLING SYSTEM1, R...",oi , Tank Tube2. Radi.n or H.,... - To En.,,"3. CoIM>' lnel .Hen ,top" 00>1< thecool... _ in,1>0 r"""""';' ,..k.of.... II>rou" the ......"'OIr unk o;>peninl .Visual L9ak Impecti onAnyt ime ,h. , yOlomI",. , wat.r, in,petl f ",I..ko.-Checkthe. atl all t he t ao. witc h w;r< o n th o o neofthefan r,wont ing h0 . 1. no t ightonvl!IOinll .h.fln., be lUre to....,... it .1 .1 1with tho fin.A. TopSCaling Seat B. Bottom Sealing Sealo Runthe gun following lhe co. e lin direeJI)O . ndUk< outthe chOli n ten,;""er,A. Ten, ioner B. M(>un ting BolbENGINE TOP ENDe Be, uret heQ-ringi, inpi,,,,, intheton, i""erbody.el nH.1I the ten,lone, to t he cronke, ,,,.e Aftc, in, t. ll. tionof t hoten, ioner, unc, have ju" fini,hedopeni ng "" d clo'i ng(mo>ing downward, ondupw"'d' i.OTumthe crankshaft in thc..medirectionuntil the"2T" mark"" thealternator rot or i, . Iigned withthenntoh in t he in, pection window in the , Itemalor co>.,(Compre"i"" Stroke TOG).oTum t he cranksh.ft clockwi, e ,bout 90'.e RemOl" the cam, h,h choin ten, ionerC. m,h.ftChoin Ten, ioner Removal).e Remo>e the..m,h. ft lOp chain guide boll" ,ndremo,e t he guide.A, Top Chain GuideENGI NE TOP END 4-9"e Kerno t h."m,hah oapbl h, andrem."elhe cap.ni' , ti ll at TOC, andrdju' l i f nece, m y,engage,h. cam,lu ft chain with (he c. mo Manual the fol-lowing._n rooghly warm up the engi,w SO Ihat oilbu ildup an the pi,ton on lhe pi,tonhead andoylinder heJd._ ole. n off . ny corban on t he phto n andoylinder head,2. Cylinder head ga6 mm)2. Cylinder Head Bolts 18 mm)3. Chain Guide Bolt (Upper)aRemo.. the a ll h",. bJnjo bolt.a Before ' emo' ing tho oylinder he. d, hold the earburelO'to the Jir oledner duct wit h a a Pul1 off t hecylinder heJd, and removetho cylinderhe.dga., ket ,Cylinder Head Ins tallation Notes. WhenIn' tallingthecylinder head. be ca'eful of thefollowing item"OReplace l he cylinder head giI, ket with a newone.OTiW1 tenthecylinderheJdbnl\< (.ps)J nd(ti) tolhe,pecif ied 'orque (,eeView).Ol fcylinder camp, ..' ion i' lowerthanlhe ..", icc limit,oheck Ihe following'1. Ga, leakagearoundthecylinder head - ' eplacethe g"kel J nd check the cylinder head forwarp.2. Condit ion of the ..I, e "at ing.3, Val.e cle.. arlOe - if a valve,equire, ., unu,u. lly. djuHment 10 ubt. in proper clear.",e. the val, emay be bend, and not >eati ngcompletely4, PI" on/cylinder clearanoe. pi, ton , ei, ure.5, Pi;lon ring, pi' tnn ring groo, e.Cylinder Head Removala Roma.. the fol lowing pJ'''.FJi' ing (, 0lemhly: 57001-2412.Adapter: 5700 i-1202oAfter cylinde, head in,t all.l ion. in.WII t h, frontcamshaft "h. i"guide JlIhuwn.Cho,n GuOd.l n" .II.tiont heare. aroundIhev_lyeto ahout 120-150C{248- 302'F), andhomme, lightlyon -. Ive-guide arborI, pecial tool) to ,emove the lllJ idc from t hetop of the head.VI IGuideAomo,.11. ChJi n Guide2, No SIJck3 Fil he.,1. V_I,e Guide Arhor: 57001-1203therear o>m.h.ft eh. in guide bult lupper) tot he ' pecified torq"ebee Exploded View)_"Tigille"t he oil h",e banjobolt 10 the , pecified tor queI>ee Exploded View).Cyl inder Head Disassembly and Assembl y(Val ve MechanismRemoval and I nsrallari on)_U", yolve ' pring Compr.,,,,r . " emblyl,peei_l t""l) topre" down the v_l, e, pringretoiner. andremove the, plit keepe" ,_Valve Guide 10'UII.tion,OAr r ly oil to the-. I,e guide outor . urfJce beforein'tJllation.oH..t the ..ea oround t he v_lve guide hole to , bout 120- l$O'C (248 - 302' F).COrive t he v_I'eguide in from Ihe top of the hOod u, ingthe ' ol,e guide "rb",. Tho f lJnge ' lup, the guide fromgoing in too far.oRe_m Ihe val,. guide with" valve guide re"mer (, pec,,,11001 ) e, en if Ihe oil guide i, re-u", d.414ENGINETOPENDV.I Guid. Aoom...1, V. lve Guide Reamer, 570011204A. Str>ighledgeCylindor Hood WorpB. Thiekne" Gauge. Val, e In' tollalion.OChockto soc t hat lhe" I, emove, .moot hlyup anddown in Ihe guide,oorcc r toIOClh dl thevalve SCali properlyin the valc,eat. If il doe. not, rep.i r t he , . Ive ...lV.I ... . nd Spring.0)1. V. I.. Stem2, Spring Sear3. Oil Seal4, Inner Sp' ing5. Outer6. ValveRetainer1.Spring Seil8. Clo, ed End Coil9.Split Keeper0.05mmCylinder Head Cleaning. Before ioe,q'" . diWin. wewIoe. (yl ind..H.,dDi",...mhlyandA. ..mhIYI.-co.!.. I ,..,withmachini, l'.dy e. Pulll,h". intothegukI._R" l.tl O 1M 1... the 1 with.l. pp' nl l ool l l>t ul..OIl!, and elne following I" ocedu,c.Us..t Hold., . nd Ilo'Hold. , -1>5 51001 120857001-1128Mark, St . mpO(l on th o Cut*:The mdrk, 'tamped On tho back uf l he oulle,,epro..mthe 60" Culter angle37.5. . . . . . . Outer didmoter of ..Vo"" U"",,,,- .......ENGINE TOPEND . -19' - - -IV.I ",ide\3.,MeasuringV,'ve-t o Guide Cleantnce(Wobble Mtl rhod)If.. "". 11bo ro 8"08" II not >vail. hl. , in,pelltr h.4dmot in8 "",foOt e.epringWi!> romo" d, U, episton pinpull.r m embly (, pe beforecylinder mdpi'lonremo,. l,Pol ili,," t he crank, h. fl . t comp"" ion ",ok. TOCfor thoNumb. r2pi'ton, .nd lhenlu rn'hcclockwi,eJbout90',

Fucl TaokCool>nl D"iningRJdl>torMuff ler(.,burow r {PuII t ho rearward)C>m..t1af! Chain Too'i onerI{' ar ( am,h. ft Ch.in Guid.Bolll Uppor)Cyl inder H..d CoverCylinder H. >d_Rom",. l ho w.te, pip. boll >nd t ake off ' hepipo fro m Ine wale' pump._Romove lho it onlyenough 10 in".11 i' and no more.COo not , ... ..defo, ,,,.evlin"', w. U.,nop , inljO. o. , omo 1w..bnndTllt y eouldfill oul I nd, eo'otho_Po,i lion each pi'lon ring so th l he op.ning in lhe top.i ng . nd oil 'lcel .. ii, Me facing foward, nd the, . condfingondoil 'i ngexp. nderr.ee . here... Theopening, oftheoil ring , teel roil, mU'1beaboul 30- 40 of Jngle from lhe opening of . he ,opring.ENGINE TOPEND 4-23PistonRing, PistonRing Groove Wear"Check f,.- un""enKruuvewedrbyin, peeti ngt he ring", ., ing.*Th. ring' , houldf il perfocl lyp. rallcl 10 t hegroo. e" " fa.... If no' , lhe pi"on mu" be 'Oplocod..wit hthe pi,ton ring' ;nt hoir groovePJ "41 01 , no.............................................................................'10IAIO............................ .. .. ............ .................... .. ...........aorr nos-eCLUTCH 5-6kif t ho clutch cannot be . dju, t,d by t hi, mOl hod,in, peet the clutch pam,_Tighten t ho knurled locknut at t he olulCh Ilu tel, nec ""y. Ifrem"".d,the oil ..al r.pla ""IJfJ N ..." In _ 10 -;", IN .,,;dt .,..oR _ Ja.,n-.r ''''J' _ _ """'Of""'",".INt>iI... .."..1.6LU LSE or SFcl. ..SAE l OW'O, 10W50,row. O. '"2OW50R ui.-d AmountW l ilt.. it no1 ....... I'od,_liI_ io """,,,I'od:Engino OilG,a d. :Vi"""i.y:.. I..... oil filt.... 10hed ..","", .........it . ittl . _""" t- Oi lIndBolt ModInolll ll. ion No!e, ).ea.""" the . 1 the d"inp1u, IOfdomogo . tho Iol,;lo,,,, . ,ttl.- oneif it i. d ....,...._>\Ile r the oil h.. . When in>ertingt hefront engine mountingbolt. ">e jack under t he engine tolift t heengin .A. Upper Mounting Bolt7-4 ENGINE REMOVAL/INSTALLATI ONCRANKSHAFT/TRANSM ISS1ON8-1Crankshaft/TransmissionTable ofContentsT.......iooion .. .. . .. Ex...-NI SlIott _R..._.. __. .Exlno1 Sl>if! Ill_ om . . _ _ , .SpoCIiao...... . . . _ _ . .s.-:;. Tool . .SoNI.-.t . . . . .. _.Cr_ c.e sPinir'll . . .. . . . ........o-cae Splitting . ....0_ ""->lbly . . . . . . . .. ..._Cf Ex"'-'IJI' _..Cr.nk,n,lt/Cor>ro8ctlng Rod., .. ,Crank' haf' Re"'ovol. . ,Crank, haltIn"ollot i"" Ne' n ,Ccnntcti"ll RooR_II .Con ntcti"llRooIn .O _ ....It/Connoct'''II Rod0-,,,, . .CtJnnooctl", Rod_ . .. ... .Connootri", Rod Tw"" _c.:.rw-n", Rod8,. End S".CI_alll .Con.--ti"ll Roo8 1g End ae.;"11l nooortlO..,kpin W_ .. .. .C' ....k"""ft Ru nout . , , ...Cunk.h.tt M. in In, o,' /Journ. 1Wg.... .CrI Mk. "-&" Sid< 0_ _ 1 , e-.c.- .BoI_ R"""""" .B_ ,..U11 IMI"" N, . SNI , _ inll I_ VJoumoIW6o< _ . .. .sc.... -...."" a ",c1> .. .... .. .S , Met DO'Outdo R_ I .._S ,Mot< Outd>Inst ollootion Not .StI" .."e,DO' Clu,mDi_blyStor' ", Met ", Clu'ch A...",bly Not .. ,Sta r,.. "e'OI' Clu,ch InolWCti "" . , ..,... .1",,,llo1ionNma_. _. ... . ... .Eo' ..... Shift Mocho niom I_ioon ...Tr_ _ Sh&ft R..-.. .. . _nonom;o,ionShaft ' m"llo, ion .Od ... Sh,l t Oi "'bly. . . , .O, i, . Sh.lt A "'b1yNot , , .Ou'pu. Shit!Di "'bly . . . .. ..Output Sholl AuemblyNOln . !iN1l Drum_ fcrkR...-.I . . .Sl>ilt O. cm _ f ork ' ....I...i"" ... . .Shift 0 tm-Dly NoM . SI'Oft 0. Ne"," . ... ..- 1od00'of. Noul r.J Switch ,(;on;ng Bolt6. h l .mol 8h ;6. Dri.. s_ It ModI... i,... R.. S7. 0..,,,,,. $110ft ",n pring Pine.2CRANKSHAFT(rRANR.......... SMISSION

- ... ___ _._ - .._ ...,. ....., - .'\>--'""In}CRANKSHAFTfTRANSMISSION8-3G: Apply Lh :LAft-H. nd k m104 in-IblT1 :12N-m(l .2 T2: 15 N-m11.514.5 ft -IblT3: 20N-m 12.0 kg:.."18.0 ft .lblT4 : 25N.m I2.6kgT5: V N-m 12.8 25 ft. lb)T8 : 34 N-m 13.6'51T7 : 69 N-m (1.0 kt- m,.... CRANKSHAfTnRANSMISSIONSpec:ificlotiomh.mS""'..S.rviollimiter...lNft. ConnectingRods:Cormecting rod bend - -- O.2l100 mmConneet ino rod twist --- 0.21100 mmConnleting rod big end side cle.antaD.13 _0.38 mmD.50 mmConnect ing rod bigeod bearinginsert!cran" pin clearance O,031 - 0.059mm O.10 mmCra.... pi.. diameler: 29.984 - 30.000 rnm 29.97 min 29.984 - 29.994 minMarking0 29.995 - 30.000 mm,Co.... ect ing rod big end botediameter: 33.000 - 33.016 mm - --Nona 33.000 - 33.00BmmMarking0 33.009 _33.016 mmConnect ing rod bigend bearinginie rt thickness: White/ Blue 1.490 - 1.494 mm - - -White/Black 1.485 - 1.490 mm ---Whita/BrowtI 1.4BO -1.485mm ---Cormo!ct ing rod big end bearinll insert select ion:Con->, and takenff the connecu ng rod and cap withthe bearing In..m,Connecting RodInr tallstion Now._To minimi.e vibralion, a p.ir of connecling rodhouldt ho me weigtll mark. Thowoight mark i,indicoted bya copil.1lell.r, and i, .umpedonthe rod bigend,Connoctlng Rod BondSoI""Limit : 0 .2/ 100 mmWoight Mo'kLocotion Connocting Rod Bond M... ufOmont1. BigEnd Cap2. Connecti ng Rod3. We ighlMark, Alphabetl00mm""CRANKSHAFT/TRANSMISSION811Connoeting Rod Twi"M...." omon.Connecting Rod Twiste Me",ure conneoh connecting rodparJllel tot h. criUlkshall .0t hdl lhepi..l igage will becompre".d bet ween ,h. crankpin and l he beiringi ",ert.Oln w,(ninsert>p"int. d white/b lu. . Chk in..rt!crJnkpinol.,rancewith pla" ill"g.. The d.orance may oxceed the' tanddrd , Ii&h l ly, but it must not b. Ie" t h, n, h.minimum in ord.r toovoid b.. ring,. izure._If d rancoexceedt the ,"rv ice limit, replacethe crank, haft with a new one.*If themeasuredcranlpindiamete" ..enot I.., thant he service limit, butdonnt coincidewitht he originaldidmeter marking< 0 0 t he cr. nhh.ft. make new mark,on it.Connecting Rod M. rk l OC: l tionC..AIl o,""y 10 ....... ...re l he runoul . TM bel W..,.,lIi&ho," . nd 10"'1'01di,1il"U1l"reodin" {Tl RI i, III. , moun' of runoul,*If IhemM",,.m.nlIh. >er> i, elimil, repl;oc.IlIo , ..nk,h,h.Cr_ tho" Aunout$en.e< l imit: OJ mill TlAcr...""'1t A.........oer."krJu,ft Mlli n 8Nring Imen/JoumM W_.. inwftr,.,..,..l ... _ ;. __ed u .(Pf'e'II ,.1. ,""ich ;. .........ed into .....de.f...... to be m ' ed. TMlncllc.ol'"lhd.... tori... ... """ ..f ,,'"" be ot...iMd.$undonl Ti reo(, .......... t._.100/801DUNLOf'Il63OF DUI\I LOf' 11630t __rt>.- _ _ ,.,.;" ..-_.__.u_2 rnm Up to 130 hll/h (80",pill3 ...... 0- 130 k""" 180 ",pilll,l", ,,,, mm1, DepthTire TrHe rimfIan....one! b.. b..d. I""QJI tho OCR ..e Ii '" ..,...;n.. " heo' 1l>etirebumv.1! in!he rimn ,l Of.r....1earin&" blow . n\,dirtorfo... ign prtide, out of thohub wil hcompre,,,,d airt o prevent conumin.tion of thehearin&, .oln, pcel the bearin&, and replace themil nece,,.ry.Lubricate t horn.nd in' lJ lI Ihorn u, ing t he bearingdriver.' " (.peei .1 101 ') '" Ihat Ihe marked or ' hielded, Ide' lac< out.B. Circlip A. S,..,edometer drivon, Of " ' pongyf..ling",o lt at t he c,lip,,", andt igbt on;tloosely.e Rem""e lh. " Iipe' munl;ng001" andlakeoff th.caliper.e Di\Conn,,, ' t he br"k. hos< f,,-,ml!'to cal iper.* If lhofro nl Of roarcaliper i, t obedi.."omblcdJf torremov.1andifcompre'stonl he following >ler ' before di, con-neet ing tbeho, e frum t he caliper,A.Cal iperB, C. liper Mount ing Bol l>................ ........................ .. .... ............. ......... .... .....NOTECalipersFront CaliperRemovale Pu! l he ", " loco y, le on center ,t , nd,e l oo n the b. nio bolt at thecaliper, , ndt ight. " itI" ",ely.e Romove t he calipermou nt ingbo ll> and off t becaliper.e DiIConn. o..rheat; (c) thereis . large difference in left . nd , ightpadwe. r;(d) t he ... 1 i, stuck tothe pi, ton, If the fluid,e. 1 is '.pl"ed, replace the du,t", al ..well. Ai' o, "' .place all ",.1, e..ryother time lhe pad, arech.nged.3. Push t he caliper hulder.1, r. d2. Calipef HolderBrake PadRemovale Remove the caliper (, ee f ront orRear C. liper Remov-.1). . ._-rake off t he pi' ton . ide pad !, om the cal,per holder.e Pushthe caliper holder to lhopl'lon, ide, andthonremOve t he pad from t he caliper holder ,hafl.Pod R.m.....Bralce Pads...,.",.." , .. " , " .."". " ", , ",...." ,.." .., " " .""." ", " ", .3. Fluid So>14. Do" se.1I , C. lipr2, Pi,'onlHI BRAKESRer M". rerCylind,.r R,.mavale Remo"e the rollpin and thenpUll Ihe pin out of t hef'U,hrod d ovi. and brake pedJ I.e f{emDVelhe banjobolt tod"ronneCl t hebrakeho,",fromt hema,l er cylinderndlemporar ily,ec ure t heendof thebr.ke ho to ", me high place to h. p fluid10" toaminimum. There i' a flat waod fluid FrontMlJster Cyiinder DisilSS8mbl yNotese Remove t he front m.,ter cylinder fromthe handlebJr,e Remoyet h, r..."oir oap . nddiaphr. gm, andemptyoul t he brake fluid.e Rem"" e t he locknul andpivot bolt, andr, mo,"thebrake lev, r.eSlide Ihe dU>l cover out nf it' plac"e RemoY< ' he retainer with a ci rclip plie" and pUll Out 'hepi, lon wilh >elail the rubber cap, unt hebleed ..Iv. , andehe; any,pilied fiuid ,hOrok. , 0.... ' thop, . cout lon. Ii. tedbelow.I WARNINGI1114 BRAKESBrake Hose Replacement_Pump t he brake fluid out of t he line ., exploi ned in t heOra ke Fluid Change in Orake Fluid Section._Remove t he banjo boltx . 23 (1mL oi llF",k oi l 10..1: 205 2 mm belowf ,om101' ofinn.. W!>O Ifully comp,e""'.wittlou. moinFIt C. Lowe!Clam p BoltB. ForkLeg_If the fork leg w"di..."emhled, checktheforkoillev.1._Tighten til . following boll l to thesped f iod tor que ,Upper and low", ClampBolls (_ Exploded View)Calipe i, repairedor roplac. d,_Temporarily ..", mble lheInnerandouter t ubo" andpump t hem i>a< l and forlh m. nually 10 eftlon. In,lanthe upper 'teel b. lI, (19)andlower Sleel ball, (20). All the "eel b. lI, are thef ttlt>!f>"g Br.:bt R_ >4IRefe< '" lheBoor Mo,....j ""tina Uw 10I"";"e-Cit iJnol .--,.'"rnnoow therrodf\er ............

IIFront Part of Rear Fender fnstallaulJfl_In,,,,ll the""""nlinl bol".nd",. >hor. intho>OIllin.1politi"" (oee h plorembl .Bro. hlnopection . .Bru.h SpringInspect ion . .Commutator Cleaning000In, pect ion .Armatu raInspect ionBrush l eadI....peced, or t h, now roplooemoot willwon f.iI ' g.>in .OMake ", re.11con nocto"in thecircuit arecle. nandl ight , ondo,,'ni no w; rel forof eproperly i nd t he regul" ",!rec' ifieri. d.m:og1"' "'WiR v v,-,Hn400 n200 n200 nwon"'-- -- -SkU an soon wo nwo n010 HI'"10 en10 ec 10 kfl toa en'Ben- - - - -- -- - 008I'" WI'- -- - -"T 200 I!'",- ---wo na' 00 nI'"v- ----600 n' 00 a-, v-----000nAegu l.to. / Ro of the...Regulator InspectionToIe"t heregulator" ut oft",me' teppedpor t ion.06e ,urethe, lenderO-ring i; inpi",. on tho bru,h , ideyoke end.l he yo ke not.. ahead,and the low be.m will blind oncoming dri,e"._ Put a Philli!" ""ewdrl,er Intome, ertical .dju'lefguide._Turnt he adj u'ler ""t he h..dlighlinuruul to adju' ll he he.dli.ht , ert ie. llv.blewire.* 11 the I. n t urn, . i", pen the fan ,w it ch*I fthe fan d"", nol tU'n' ,in, poct t he following,Junct ionIlorein' tili led .tthemeter mounting brack, !* In, wll . new d.mper where it i, _Checkto ",e tbat the rubber domper> >t thometermount ingbrackel are ingoodcoodil ioothey,houldnot be hard or cr..ked.* Replace. oydomOll"drubber dampe"with new011,-Chock to,.e t hal .11meter mount iog null" etightened," curely.*Tighlen the loo, e f., l ene"Merer or G,wge Replacement_Repl. themele, or the with thepo;nlefif neoe,SNy.Meter and Gauge AS$embly Note_In' tili! each le.d on lhepo, itinn , hown.BulbReplacement Notes_T" rOm"ve lhe ... typebulb, (indieotor ondilluminationI. pull uut the bulb , ,,,,keto . ndpUllthebull>< off the ot her t h. n t he wotortern-perat u'" gauseun;toUI gwdthe uniti, defe, _th'e.

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...__......-'-" , " .UA-,-- -,,V-,-,----i;:.. -' "'"- .::- "!J]',,[.::.- ,- - .., ,,I , \..::;::LJ-o. -f!Q-l. __ ...., TUMI .... I V l ' W,. L..'' V4W_u.o. I1- - - - --.... _ T.... !IiroI ,!'rll-. ovvfl1a'-+-0 . " '"" ._.----;:-: .. . -... , _ , 0,... "t ; , . -..-...... "" . .,-.-,'..-...... '_....' ''',.AppendixTable of ContentsAdd itional Cons iderat ions forRac ing .Carburetor. . . . . . .. ... . .. . . . .. ... . . . ... .. ... . . . . . . . . . . . .Spark Plug. . . . . . . . . . . . . . . .. ... ... . . . . . . . . . . . .. . .. . . . .SparkPlug Inspect ion ... .. . . . . .. . . . . . ... . ... . . . . . . .. . . .Troubleshooting Guide. . . . . . . . . . . . . . . .. . .. . .. .. . . . . . .. . .. .General Lub ricati on.. .. .. . . . . . . . . . . ... . ... . .. . .. . . . . . . ...Lubrication . . .. . ... . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . ..NUl, Bolt , andFastener Tightness ... ... . .. . . . . .. . . . . . .. ... . . .Tight nessI n ~ t i o n . . .. . . . . ... . . . . . ... . . . . . . . .... ... . .UnitConversionTable. . . . . . . . . ... . . . . . ... .. . . . . . . ... . . . . . ..,APPENDIX 16'16216-216-2, , ~16-2 APPENDIXAdditi onnl Considarat ions forRacingThi, mOloroycleh., bee donounder , upe"i,edcondilion"andreoognized ..nctioningbodie, ,houldbe oonta01edfor"" motor troubleBat teryvol",gelowRelay, no t ",ntact ing O' operatingS", . ter buttonnot contact ingWiring open or ,""ortedIgnit ion ,wilchtro ubleEngine>lOp , wiICh t roubleM. in fu,eblownSt t or mot or ,outi ng but . ngino doo.n, ' Urn .. . . "St arte r mol '" Clutch t roubleEngin. won'"u. n .. . . "Valve ,. izureRock. r arm seizureCylind.r, pistonseizureC nk. haft .eizureCo nnecl ing rod small end ,e izureConnect ing rod big end ' eizureT. on. mi" ion gear orb..ring . eizureCom,holt ..izureHil oulal pisl on St ond d Spo.k Plug n rood.Oi.mOlor: 10mmPitch : 1.25 mmft ch : 12 .7 mm16-4 APPENDIXNo fu.t flow:Fuelle cloAAl'dFuel t..,. air vent obstructedFu.1 lap doggedr u.ll ine cloggedFlo. t valvo doggedEngin. fl oodod:in "rbur. tor no>! bowllOOhighFlo. t womor i . diu>tedSparkplug incorre ctIC igniter troubleFuellai, mixt u' o inco"oet :Main iet clogged nr wr""g ,lrefuel l., el in carb uretor f loal bowl t oolowCarburetor hoMer 100'0Air cleanerpoorly ",aled, or mi"ingAir cleaner duct poorly ,ealedAjr cleane r cloggedCOmp....ionhigh:Carbonbuilt up in combu, tion chamberEnvlno lood foulty:Clul ch , lippingEngine all level t oo highall yl" ", il\' too Dri," l rain lroubleBrake draggingLubrication inadequate,Engine oil level t oolowEngine oil poor qua lity orincorrectCoolont incorrect:Coolant le,,1too loweo"'ant deleriorale dCool inV .y.tem cornpo nont lncorrect:R.dlato r cloggedTheizure, damageCylinder head gasket leakingExbau< aring wornCam,h.ft ohain ten, ioner troubleCam, haft chain, , prClCket, guide wornAbnormal Drive Train Noil a:e lu"'" nol..:Weak or damaged damperC1 ulcl1hou, inglfrk tion plote clearance excessi, eClulCh hou, ing wornT..n""i..lon noi, . :Bearing-; wornTron, mi" ion gea" worn or ohippedMelal chip,jammed in gear teethEngine oil in. ufficientDrl eh.ln noi,. :Dri. e ch.in adju' ted improperlyCh. in wornRear . nd/or engine ' procketWOrnChain lubric>!ion in' uffici," tRear wheel mi,.lignedAbnormal Frame Noil a:noi..:Oil in5u fficientor 100 t hinSpring weak or brokenR , .boom.. noi..:Shock amorter damagedDi", b k. noi, o:r ad in' lalled incorrect lyPad 'urface glazedDisc wa,pedCaliper t rouble01ll.r n,,;,o:a"ckel,boh, elc. not properlymounted orlightenedOil Prau ura Warning Light GOIII On :Engine ,"I pump d.magedEngine oil " re.n d oggedEngine toolowEngine oil viscmity 100lowCam, haft l>< oring< wornC" nk5h,1tbearinl!' wornOil pre" u.e ' WilCh dam' gedWiring damagedReiief . alve , t uck openO.ring atthe ," I pipe in t he crankcase domagedExhauJ1 Smokes Excessively:Whit. ,mok. :Pi,t"" oil ring wornCylinder wornV. I.. oil , e>1 damall"dV>I"gulde wornEngine oil l..el 100 highBlock .mok. :Air cleaner clogll"dMain jellOo large or fall en offSwterplunge. ' luck openFuel le..1in carburetor11 0", bowl 100 bi8hBrown , mok. :Main jc, t oo , mallFuel l..el in carburetor fioat bowl too luwAir cleoner doct lo""eAir oleaner poorly ..aled or mi>Mulfter Mounting Bolt